Method and article for attaching a structure to a surface



Sept. 1962 A. H. WALTER 3,054,713

METHOD AND ARTICLE FOR ATTACHING A STRUCTURE TO A SURFACE Filed Aug. 18,1959 frwen for Alexander-H Walzer By lzllsAzfomey 3,54,?13 PatentedSept. 18, 1962 3,054,713 METHOD AND ARTICLE FOR ATTACHING A STRUCTURE TOA SURFACE Alexander H. Walter, Halsingborg, Sweden, assignor, by

mesne assignments, to United Shoe Machinery Corporation, Flemington,N..l., a corporation of New Jersey Filed Aug. 18, 1959, Ser. No. 834,453Claims priority, application Sweden Sept. 23, 1958 4 Claims. (Cl.156-498) This invention relates to a method and article for adhesivelyattaching a structure to a surface, and particularly to a method andarticle for attaching a rigid object to a surface having irregularitieson its attaching face.

The problem of obtaining a suitably tight joint when securing an objectto an irregular surface or securing an irregularly surfaced object to asurface is encountered in many household and industrial applications.Thin plastic tiles, wall boards, linoleum squares, acoustic plates, andthe like, attached as a veneer surface to a Wall or ceiling as adecorative or protective finish, are generally applied by spreading asuitable adhesive over the entire surface of the wall or ceiling, andthe veneer surface is then pressed against the cemented surface. Due tothe unevenness of the surfaces of walls or ceilings this often does notprovide a satisfactory over-all adhesion, and in time, after theadhesive has dried out, the adhered surface may be loosened byvibrations, or foundation movements.

The problem is also encountered in other relations such as the temporaryattachment by adhesives of wooden heels to womens shoes. In thisinstance, firm pressure is required to flatten out the irregularities ofthe heel seat of an upper against the shallow upper surface of the heelfor a close fitting joint. Otherwise, an intervening gap is filled withthe considerable quantity of adhesive needed for adequate bonding which,upon hardening, prevents the tight fitting union of heel and uppernecessary for satisfactory permanent fastening. Also, this temporaryjoint must be strong enough to hold heel and upper together throughnecessary handling.

In cemented joints between irregular and rigid surfaces, it has beenfound that the strength of the glued joint is entirely dependent uponthe area of the actual points of attachment of the adhesive, that is,the point at which the structure and surface are in contact with eachother by means of the adhesive. Consequently, if either the structure orthe surface have large or small irregularities, the strength of thecemented joint is indeterminate, since the sizes of the areas of theactual points of attachment cannot be known. Often the irregularities ofone or both of the surfaces may be such that a uniform coating ofadhesive will establish bonding engagement only at the high points ofirregularities, leaving large areas of the opposing surfaces which arenot in adhesive contact or a wasteful thick intervening layer ofadhesive squeezed into the low points.

It is an object of the present simple inexpensive method for adhesivelyattaching a rigid structure to an uneven surface With a strong bond.

It is also an object of the present invention to provide a means ofrapidly adhesively attaching a heel to a shoe upper in a tight closejoint.

According to the method of the present invention, bodies having rigidsurfaces presenting high points which would give irregular adhesiveengagement are secured together by at least one resiliently compressiblelinking member carrying adhesive on opposed faces by which it 70invention to provide a is adhesively secured to both the rigid surfaces.The compressibility of the linking member enables the adhesive on thesurface of the member to enter into allover engagement with the rigidsurfaces both at high points and low points so that an effective bondingarea is secured between the surfaces of the linking member or membersand the surfaces to be joined.

The invention may be better understood when described in reference tothe accompanying drawings, in which:

FIG. 1 is an enlarged cross-sectional view of the linking member;

FIG. 2 is an enlarged cross-sectional view of the linking member as usedin joining irregular surfaces according to the present invention;

FIG. 3 is an enlarged cross-sectional View of a special form of jointbetween irregular surfaces using a linking member under conditionscausing the adhesive to penetrate all the way through the linkingmember; and

' FIG. 4 is an exploded view in perspective of the heel seat end of ashoe upper and heel with a linking member interposed for making a bond.

A linking member 4 shown in FIG. 1 comprises a thin compressible sheetmaterial 6 with coatings 8 and 10 of solvent-activatable adhesive on itsopposed faces 12 and 14. The compressible material may be any porous,elastically deformable material, preferably a rubbery cellular material,such as cellular rubber, cellular plastics and cellular polyurethane, ora similar material especially suitable for a specific use intended.Felt, glass wool, and steel wool may also be used but are not assatisfactory. A preferred material is a polyurethane foam having a lowmodulus of elasticity. The adhesive layers 8 and 10 may be anycompatible solvent-activatable adhesive, preferably rubber or syntheticrubber based adhesives. Where the cellular structure is porous, oropen-celled, the adhesive may penetrate into the cells for a lockinggrip, as shown in FIGS. 1 and 2.

The composite of compressible sheet material 6 and adhesive layers 8 and10 is cut to size suitable for use as linking members 4 for a particularuse.

For securing a rigid veneer member such as an acoustic plate 16 to awall or ceiling surface 18 by the method of the present invention, thesurface 20 of the acoustic plate 16 may be coated with a layer 22 ofadhesive containing a solvent capable of activating the dried adhesivelayer 10 on the resilient material 6. The adhesive layer 22 is allowedto dry for live to ten minutes to a condition where it is still tackyand contains some residual solvent. The adhesive layer 10 on one face 14of the resilient material '6 is firmly pressed against the layer 22 onthe surface 20 of the acoustic plate 16; the adhesive on the linkingmember 4 is activated by the residual solvent content of the adhesive oflayer 22 and the two surfaces are firmly bonded. The other rigid surface24, that is, of the ceiling 18, may be likewise treated with a layer 26of adhesive containing a suitable activating solvent. The adhesive isdried to tacky condition and the exposed layer 8 of the linking member 4is firmly pressed against this layer 26 to form a bond. The solventcontaining adhesive may be also spread on the adhesive-coated surfacesof the linking member 4 and the freshly coated 5 linking member 4pressed against the rigid surface. This may be of special advantage forinstance in limited or awkward working areas. 7

The surfaces 12 and 14 of the compressible material 6 are elasticallydeformed to conform to the irregularities of the surface 20 of the plate16 and the surface 24 of the ceiling 18 between which it is pressed. Thecompressibility of the sheet is preferably such that the linking member4 is deformable by simple hand pressure, so that the surfaces 12 and 14of the sheet 6 and the layers and 8 of adhesive on the sheet 6 willconform to the irregularities of the surface 29 of the plate 16- and thesurface 24 of the ceiling 18 or wall when the plate is pressed againstthe ceiling by hand pressure. The adhesive establishes bonds between thesurfaces of the linking member and substantially the whole surface areasof the plate and ceiling leaving no unattached portions.

The bonding is instantaneous, and placement must be precise. Thestrength of the bond increases by degrees and, after a period of abouteight hours, reaches a value many times greater than that necessary formost purposes.

Other means of adhesively attaching the resilient linking members 4'torigid surfaces include the use of a contact glue freshly applied to theattachment areas of the plate 16, or the ceiling 18, and/or the layers 8and it of the linking members 4 whereon it is bonded to these adhesivelayers without the necessity of an additional solvent. In some instancesthe existing layers 8 and 10 may be activated by a solvent alone and thepads pressed into adhesive contact with the rigid surfaces.

As shown in FIG. 2, the linking member 4 holds the plate 16 somewhataway from the ceiling surface 18 so that relatively major irregularities28 are bridged, eliminating rocking points. In ordinary adhesiveprocedures, such opposing high points would produce adjacent pockets oflittle or no adhesion between the opposing surfaces. Additionally,acoustical and insulating advantages are obtained in the resilientmounting and the dead space created between the two surfaces.

For certain operations where a particularly strong union is desired, thethickness of the adhesive layers 8 and 10, as shown in FIG. 1, relativeto the thickness of the compressible sheet 6 may be such that when thelinking member 4 is pressed between surfaces to be joined the adhesivelayers 8 and 10 will be forced into cells of the resilient sheet 6. Asshown in FIG. 3, two irregular surfaces 30 and 32 are joined by alinking member 4 where in the adhesive layers 8 and 10 penetrate cellsto form a continuous body 34 of adhesive in areas of opposing peaks 36of irregular surfaces 30 and 32, and leave portions 38 in the cellularmaterial 6 which do not contain adhesive in less compressed areas ofopposing valleys 40 of these surfaces.

In another aspect of the invention shown in FIG. 4, a thin resilientlinking member 4 is pressed against the heel seat engaging face 42 of aheel 44 for engagement with an overlasted shoe upper 46 in a bond strongand tight enough for a later permanent attachment. The face 42 of theheel, is coated with a layer of adhesive containing a solvent suitableto reactivate the adhesive layer on the linking member 4 which ispressed against the heel face 42. The heel engaging surface 48 togetherwith the exposed shank portion 50 of the upper 46 are also coated with alayer of suitable adhesive and the heel 44 with affixed linking member 4is pressed in place against it. The linking member 4 is deformed tocover the numerous points of contact provided by the heel seat 48 of theupper and to accommodate the shank 50. The linking member 4 in acompressed state has a very small thickness, and is thus maintained whenthe adhesive has hardened providing a tight union between shoe heel andupper.

The following examples are given better to understand the method of theinvention:

Example I.--Sheet polyurethane foam approximately ,6 thickness wascoated on both surfaces with a known adhesive of the followingcomposition:

A solvent mixture containing 50 parts by volume of ethyl acetate, 25parts by volume of toluene, and 25 parts by volume of petroleum naphthawas combined with 4 the following combination of ingredients to make asolution containing 24% solids:

Parts by weight Polychloroprene Calcium silicate (finely divided) 5Non-staining antioxidant 2 Zinc oxide 2 Chlorinated rubber 33 Theadhesive coating was allowed to dry to tackfree condition, and the sheetwas then cut into pads approximately 1 /2 inches square.

Acoustical or sound-absorbing plates of cellulosic materialapproximately 10 inches square and A inch thick were coated with a layerof the same adhesive at areas where the linking members were to befixed, i.e., in the corners of the plate, and the cement was allowed todry. The porosity of the acoustic plate was such that, after drying ofthe first coat, a second coat was applied to the same area, and allowedto dry to tacky condition.

The linking members were then carefully placed on the adhesive coatedportions of the plate and pressed tightly to force the adhesive coatedsurface of the linking member to conform to the surface of the plate sothat the adhesive layer entered into over-all contact with the adhesivelayer on the plate. An instantaneous high tenacity bond was formed.

A ceiling surface to which the acoustical plates were to be applied wasthoroughly cleaned and dried. A coating of the same adhesive was spreadon the ceiling areas against which the linking members would press whenplate and linking member were put in position. This coating of adhesivewas allowed to dry to a tacky state. The plate with the adhesive linkingmembers secured thereto was alined in its intended position with theadhesive linking members adjacent the adhesive coating on the ceiling,and the plate was then pressed into position to bring the adhesive layeron the linking members against the tacky adhesive on the ceiling. Theplate was firmly pressed to force the adhesive on the surface of theresilient linking members into allover engagement with the layer ofadhesive on the ceiling surface. An instantaneous high tenacity bond wasformed.

On examination of a section of the union formed between the ceiling andthe acoustic plate, it was found that substantially the completecontacting area both between the linking member and the plate and thelinking member and the ceiling was in tight adhesive engagement. Theinstantaneous bonding was too strong to allow any subsequent adjustment.Plates were carefully attached in abutting relationship until thedesired ceiling area was covered.

Example II.-A wooden heel for a womans shoe was coated on the heel seatengaging face with a layer of the same adhesive composition used inExample I, and allowed to dry to tacky condition. A one inch square ofthe adhesive-coated sheet material, prepared according to Example I, waspressed against the adhesive on the heel seat engaging face. The heelseat area of the upper was coated with a layer of the same adhesive andallowed to dry to tacky condition. The heel was located carefully withrespect to the shank and the heel seat area of the upper and thenpressed into place to force the adhesive layer on the free surface ofthe linking member against the coating of adhesive on the heel seat. Aninstantaneous high tenacity bond was formed. Upon examination, the shoeparts were found to be united in a strong bond capable of withstandingfurther handling in manufacturing operations.

Since different embodiments of the above invention may be made withoutdeparting from the scope thereof, it is intended that the above examplesand drawings should be considered as illustrations of its use and not tolimit its application.

Having thus described my invention, what I claim as new and desire tosecure by Letters Patent of the United States is:

l. The method for securing together bodies having rigid uneven surfaceswith high points on at least one of said surfaces, comprisinginterposing between said bodies a plurality of spaced linking memberscomprising thin resiliently compressible porous open-celled cellularsheet members substantially less in over-all area than the surface ofsaid bodies and layers of solvent-free, solventactivatable adhesive onopposed faces of said sheet members, providing coatings including asolvent for said solvent-activatable adhesive between the surface ofeach of said bodies and the adhesive layer on said sheet membersadjacent said surface, said solvent activating the adhesive on adjacentfaces of said sheet members, and with hand pressure pressing one bodytoward the other to compress said sheet members between said surfacesand cause said layers of adhesive to permeate said porous open-celledsheet member and to conform to said surfaces and to enter into intimatesubstantially allover adhesive engagement with said surfaces.

2. The method for securing together bodies having rigid uneven surfaceswith high points on at least one of said surfaces, comprisinginterposing between said bodies a plurality of spaced linking memberscomprising thin resiliently compressible porous open-celled cellularsheet members substantially less in over-all area than the surface ofsaid bodies and layers of solvent-free, solvent activatable adhesive onopposed faces of said sheet members, providing coatings including asolvent for said solvent-activatable adhesive between the surface ofeach of said bodies and the adhesive layer of said sheet membersadjacent said surface, said solvent activating the adhesive on adjacentfaces of said sheet members, and with hand pressure pressing one bodytoward the other to compress said sheet members between said surfacesand cause said layers of adhesive to permeate said porous open-celledsheet member and to conform to said surfaces and to enter into intimatesubstantially allover adhesive engagement with said surfaces, saidlayers of adhesive providing a quantity of adhesive per unit area ofsaid sheet member to flow together to form a continuous body of adhesivein the cells from face to face and through the thickness of said sheetwhen said sheet is deformed with the adhesive in solventactivatedcondition.

3. A method for attaching a sound absorbing plate to a ceiling surfacecomprising interposing between the rigid surfaces of said plate and saidceiling a plurality of spaced linking members comprising thinresiliently compressible porous open-celled cellular sheet members lessin over-all area than the surface of said plate, and layers ofsolventfree, solvent-activatable adhesive on opposed faces of said sheetmembers, providing coatings of adhesive solution including a solvent forsaid solvent-activatable adhesive between the surfaces of said plate andof said ceiling and the adhesive layers on said sheet members adjacentsaid surfaces, said solvent activating the adhesive on adjacent faces ofsaid sheet member, and with hand pressure pressing said plate towardsaid ceiling to compress said sheet members between said surfaces andcause said layers of adhesive to permeate said porous open-celled sheetmember and to conform to said surfaces and to enter into intimatesubstantially allover adhesive engagement with said surfaces.

4. As an article of manufacture, a linking member adapted to securetogether bodies having rigid uneven surfaces comprising a thin porousopen-celled cellular resiliently compressible sheet member and layers ofsolvent-free solvent-activatable adhesive on its opposed faces, saidsheet member being elastically deformable under hand pressure wherebysaid layers of adhesive on said faces will conform to irregularities inuneven surfaces against which said linking member may be pressed andwill enter into intimate substantially allover engagement with saiduneven surfaces to provide a relatively large bonding area between saidsheet member and said uneven surfaces to be joined, said layers ofadhesive providing a quantity of adhesive per unit area of said sheetmember to flow together to form a continuous body of adhesive in thecells from face to face and through the thickness of said sheet whensaid sheet is deformed with the adhesive in solvent-activated condition.

References Cited in the file of this patent UNITED STATES PATENTS1,959,322 Wedges May 15, 1934 2,246,101 McEnany June 17, 1941 2,389,210Pitman Nov. 20, 1945 2,559,609 Faust July 10, 1951 2,578,709 LyijynenDec. 18, 1951 2,644,280 ONeil July 7, 1953

1. THE METHOD FOR SECURING TOGETHER BODIES HAVING RIGID UNEVEN SURFACESWITH HIGH POINTS ON AT LEAST ONE OF SAID SURFACES, COMPRISINGINTERPOSING BETWEEN SAID BODIES A PLURALITY OF SPACED LINKING MEMBERSCOMPRISING THIN RESILIENTLY COMPRESSIBLE POROUS OPEN-CELLED CELLULARSHEET MEMBERS SUBSTANTAILLY LESS IN OVER-ALL AREA THAN THE SURFACE OFSAID BODIES AND LAYERS OF SOLVENT-FREE, SOLVENTACTIVATABLE ADHESIVE ONOPPOSED FACES OF SAID SHEET MEMBERS, PROVIDING COATINGS INCLUDING ASOLVENT FOR SAID SOLVENT-ACTIVATABLE ADHESIVE LAYER ON SAID SHEETMEMBERS SAID BODIES AND THE ADHESIVE LAYER ON SAID SHEET MEMBERSADJACENT SAID SURFACE, SAID SOLVENT ACTIVATING THE ADHESIVE ON ADJACENTFACES OF SAID SHEET MEMBERS, AND WITH HAND PRESSURE PRESSING ONE BODYTOWARD THE OTHER OT COMPRESS SAID SHEET MEMBERS BETWEEN SAID SURFACESAND CAUSE SAID LAYERS OF ADHESIVE TO PERMEATE SAID POROUS OPEN-CELLEDSHEET MEMBER AND TO CONFORM TO SAID SURFACES AND TO ENTER INTO INTIMATESUBSTANTIALLY ALLOVER ADHESIVE ENGAGEMENT WITH SAID SURFACES.